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CONFIGURABLE MOTION
CONTROL PLATFORM
User Manual
Conformities
Declaration of Conformity EMC Directive
For PMC components there are declarations of conformity The PMC products of a drive system mentioned in this
available. These declarations confirm that the components documentation comply with the requirements of the EC
are designed according to valid EC directives. If required, Directive (see page 67).
you can ask your sales representative for these declara-
tions. CE Label
Low-Voltage Directive
The PMC products of a drive system mentioned in this
documentation comply with the requirements of the EC
Directive (see page 67).
Safety Instruction
Please read before the initial startup. See page 73.
AxM II
CONFIGURABLE MOTION
CONTROL PLATFORM
User Manual
Supported Models
(Rev. 1 - Nov. 2011)
2 Content of the
Package
3 Electric Installation
4 Hardware Description
5.1 User Connectors (U1 /U2)............ 37 8.1 AxM II / AxP Drive’s alarm list...... 64
5.2 Encoder Connector (E1)............... 38
5.3 CAN connector (C1).................... 43
5.4 EtherCat Connectors (IN/OUT)...... 43
5.5 AxM II S1 Power Connections....... 44 9 CE conformity
5.6 AxM II S2 Power Connections....... 46
5.7 AxM II S3 Power Connections....... 48 9.1 Introduction: EC directives........... 68
5.8 AxM II S4 Power Connections....... 50 9.2 LVD Directive............................. 68
5.9 AxM II S5 Power Connections....... 52 9.3 Product Safety........................... 68
5.10 Connection Example................... 54 9.4 Application as Directed – Scope of
Application................................ 68
9.5 Installation................................ 69
9.6 EC Declaration of Conformity and
6 First Installation and Directive EMCD.......................... 69
Tests 9.7 Installation as Specified.............. 70
9.8 EC Declaration of Conformity....... 70
6.1 Needed for First Test................... 56
6.2 Minimum Connections Outline...... 56
6.3 Cokpit Tool Start up and Parameters
Configuration............................. 57 10 Safety instruction
6.4 “Basic” Mode Definitions............ 57
6.5 PLC Application Use................... 58 10.1 Important directions for use......... 74
6.6 Firmware downloading ................ 58 10.2 Safety Instructions for Electric Drives
and Controls.............................. 75
10.3 Instructions with Regard to Specific
Dangers..................................... 77
7 Emergency and power
fail condition handling
Summary | 5
1
Overall
Dimension AND
TECHNICAL
SPECIFICATIONS
Phase Motion Control
AxM II / AxP Configurable Motion Control Platform
1.1 AxM II - Size 1
148
19,5
5 65,50 8
5,50
0,20
166,5
126
5,50
78,5
21
Install inside a switchboard avoiding any obstacle for cooling fan air flux. To avoid any de-
rating of the product performance, do not place objects less than 10 mm from the cooling
plateside.
Technical Specifications
Phisical specifications Value Unit
140
100
60
10 40 60
TEMPERATURE
% output current variation versus room temperature
ARMS
4
3,5
2,5
1,5
Operating area of AxP 02.05.2 drive as function of output voltage, in case of 220V or 265V
power voltage supply.
ARMS
9
2
Inom (265 volt)
Operating area of AxP 06.14.2 drive as function of output voltage, in case of 220V or 265V
power voltage supply.
06
04
02
Operating area of AxM II 04.09.4 drive as function of output voltage, in case of 220V or
380V power voltage supply.
14
ARMS
12
10
08
06
04
Operating area of AxM II 06.14.4 drive as function of output voltage, in case of 220V or
380V power voltage supply.
12
10
08
06
04
Operating area of AxM II 09.20.4 drive as function of output voltage, in case of 220V or
380V power voltage supply.
Technical Specifications
Technical specifications (1)
AxM II 20.40.4 AxM II 35.70.4 Units
(1) Test performed with full option control card and firmware 1.4.291 - (2) Peak rms current - (3) Including input rectifier losses
40
30
20
Imax
(480 volt, Vout)
10
Imax
(380 volt, Vout) 0
0 100 200 300 400 500
Vout
Technical Specifications
Technical specifications (1)
AxM II 70.140.4 Units
(1) Test performed with full option control card and firmware 1.4.291 - (2) Peak rms current - (3) Including input rectifier losses
100
90
80
70
60
50
40
30
Imax
(480 volt, Vout)
20
10
Imax
(380 volt, Vout) 0
0 50 100 150 200 250 300 350 400 450 500
Vout
Technical Specifications
Technical specifications (1)
AxM II 90.150.4 AxM II 110.180.4 Units
Voltage supply 0 - 460 ± 10% Vac 3 phase
Auxiliary feeding voltage 22 - 30 / 6A Vdc
Input current 150 180 Arms
Frequency 0 - 400 Hz
Nominal power 45 55 KW
Current output, axis < 100 rpm, S1 90 110 Arms
Current output, max speed, S1 78 94 Arms
Peak current (2)
150 180 Arms
Power Losses total (3)
1750 2130 W
Maximum voltage output Vin x 0,95 Vac
PWM 8 / 16 KHz
Efficiency at nominal power 97,4 97,4 %
Input form factor 0,9 Vac 3 phase
Maximum braking current 100% of peak current --
Cooling 3 fan 92x92x38 / flow rate: 840 m3/hour
Dimensions (WxHxD) 259,2 x 698 x 320 mm
(1) Test performed with full option control card and firmware 1.4.291 - (2) Peak rms current - (3) Including input rectifier losses
150
AxM 110.180.4
Imax
(480 volt, Vout) 100
Imax
(380 volt, Vout)
AxM 90.150.4
50
Imax
(480 volt, Vout)
Imax
(380 volt, Vout) 0
0 100 200 300 400 500
Vout
Technical Specifications
Technical specifications (1)
AxM II 160.320.4 AxM II 200.400.4 Units
(1) Test performed with full option control card and firmware 1.4.291 - (2) Peak rms current - (3) Including input rectifier losses
300
AxM 200.400.4
Imax
(480 volt, Vout) 200
Imax
(380 volt, Vout)
AxM 160.320.4
100
Imax
(480 volt, Vout)
Imax
(380 volt, Vout) 0
0 100 200 300 400 500
VOLT
Connectors’ Set:
User Connectors (U1 and U2) with identifiers and polarity keys,
Power connectors (P1),
Relay connector (R1),
Encoder connector (E1),
User’s Manual:
A CD with a copy of the Phase Motion Control Internet Site where You will find:
Firmware:
PII2D controller The Firmware runs the operative system and all basic drive’s resources: current, speed and
4 compensation position control rings, fields bus managent, protections and diagnostics.
terms are available:
proportional Further peculiar features of the firmware are:
(speed), differential »» Full digital control of the direct and quadratic current, updated at 16 kHz frequency.
(acceleration), »» Digital speed ring with zero real speed, PII2D controller1 with generalized feedforward.
integral (position)
and integral of The firmware is originated in the Phase Motion Control Labs and it cannot be altered by the end
position (to obtain a user. Periodically firmware updates are released and they are made allowable on the Internet site
zero position error). http://www.phase.eu. Compatibility of new updates with previous applications is allways assured.
The Application includes the motion program and the logics runs. Logic LAB is the ap-
plications’ developement tool. This tool allows the customer to make his own automation
programs. Within the limits of the allowable I/O and program memory, standard automation
functions of IEC 1131-3 PLC can be used: but they are usable in a so fast tool that a very
refined real-time motion control can be accomplished; moreover a data acquisition function
from two separate encoders is included. The PLC software performs in cycle two different
tasks: one fast, used for the motion control functions, with a 8kHz cycle frequency; the other
slow with user-programmable cycle frequency ranging from 15.625Hz to 1kHz for all general
auxiliary use. The Logic LAB language is so powerfull that very fast functions as positioners,
electronic, path control, are easily executable by the end user. Which can therefore upgrade
the AxM-II / AxP to be a control center of the whole driven system, using his proprietary
software entirely protected against imitation and competition.
Together with AxM-II / AxP drives a set of Standard Applications are supplied with source
code. In details following applications are supplied:
Basic
The “basic” application allows the user to control motor’s current and speed like needed in the
usual classic drive control, it turns AxM-II / AxP in a versatile brushless servomotors digital control.
Speed-V
» Store capacity till 4 complete sets of parameters (tasks); enabling the user to shift
from one set of parameters to another in running time by digital inputs;
» Electric shaft;
» Encoder simulation
Positioner
This application allows the use of the AxM drive as programmable multi-position positioner.
The main features of Positioner are:
Power connections:
AxM II drives are Connect tri-phases power supply to the R, S and T terminals of the power connector P1 using
designed for tri- a 3 + 1 shielded cable. Use one GND screw of the drive to connect the cable shield.
phase supply only; Connect single phase power supply to two pins of R, S or T using a shielded cable as well.
voltage must be
lower than 460V
(+10 %). Braking resistor connection:
AxP drives are The internal braking resistor is able to dissipate a maximum of 10W braking power. If the power
designed for tri- dissipation is higher, it becomes necessary the use of an external resistor. To activate the in-
phase or single- ternal brake resistor short-circuit the pins BR+ and DC+ of P1 connector. Connect the external
phase supply; resistor on the BR- and DC+ terminals of the same connector. Check also par. 7.4 and 7.5. The
voltage must be minimum and maximum ohmic values for such external resistor are:
lower than 230V
(+10 %). Model Min Max
AxP 02.05.2 43 56
AxP 04.09.2 24 32
AxP 06.14.2 15 20
AxM II 04.09.4 58 75
AxM II 06.14.4 37 48
AxM II 09.20.4 26 34
AxM II 20.40.4 15 19
AxM II 35.70.4 8,8 11
AxM II 70.140.4 4,4 5,5
AxM II 90.150.4 3,5 4,5
AxM II 110.180.4 2,9 3,7
AxM II 160.320.4 1,6 2,1
AxM II 200.400.4 1,3 1,6
If an external braking resistor is used, the system configuration must be modified: you need
to set at least the Brake resistor value and power. The firmware will use these values to ac-
tivate the thermal protection of the resistor itself.
Connect the phase windings of the motor to the A, B and C terminals of the power connector
(P1) according to the sequence specified in the connection diagram supplied with the motor
and the connection outline shown in par. 7.4.
Use a shielded cable with section suitable for the motor nominal current.
When the connection cable is longer than 15 m, the use of damping inductances in series
with the cable is recommended.
WARNING:
The cable shield must be grounded on both sides, motor and drive, connecting it to the
special screw provided for.
Connect a 24V (22-30V) stabilized voltage, minimum current 0,6A to the connector U1 ac- If the chosen sensor
cording to the diagram of par. 7.1. is a Resolver, the
cable to be used
must have the
Position sensor connection: duplexes twisted
and individually
Connect the signals required by the used sensor to the Encoder connector (E1) according to shielded, in
the relative correspondence specified in the wiring table of par. 7.2. addition to the
Use a shielded cable with twisted duplexes, possibly of high flexibility type. whole cable shield.
When the connection cable is longer than 25 m, the use of adequate cable section is recom- Connect the
mended in order to avoid excessive voltage drops. individual shields
to the pin 1 of the
WARNING: encoder connector
The cable shield must be grounded both to the motor and connecting it to the drive connec- E1, and the whole
tor frame. cable shield to
the frame of the
connector.
Connect such a filter between mains and drive inputs; if more drives are used in the same
machine a bigger filter should be used.
Electric Installation | 29
4
Hardware
description
Phase Motion Control
AxM II / AxP Configurable Motion Control Platform
4.1 Power stage
»» Innovative Ac-Ac converter without DC bus electrolytic capacitor, which provides instant
availability at power-on and correct input current waveform, in line with the future IEC
555 norm;
»» Auto tuning of current limit vs. supply voltage and ambient temperature; single drive for
0-240 Vac (AxP) or 198-460 Vac (AxM) supply;
»» 8 kHz carrier power IGBT stage, 16 kHz ripple frequency, built-in full power, limited duty
cycle brake resistor; full power braking chopper;
»» Forced ventilation controlled by the drive temperature (the fan is turned on only above
50°C) to limit dust accumulation; the drive temperature is monitored and available for
programmable cycle self-limiting;
»» Full power stage intrinsic protection (overtemperature, short circuit to ground and be-
tween motor wires) with fault condition non volatile storage.
»» Control and power stages have separate and independent power supplies for emergency
shutdown and debugging
»» Real time temperature observer for each power chip, with adaptive current limit.
4.2 Connections
High speed sensor interface (E1 and C1)
»» A secondary encoder I/O (C1 - 2 MHz) wich can be programmed as incremental digital
The encoder encoder without commutation tracks or Endat serial encoder.
simulation output
can be used Encoder simulation output, line driver, with programmable conversion rate with reference to
alternatevely the main one (allovable on C1 connector)
with the auxiliary
encoder input. On the C1 connector there is also the Can interface. See the connection list on par. 7.3
4.3 Hardware
»» IP 20 Cabinet protection, with internal RFI shield,
»» Control and power interfaces with removable terminals and connectors,
»» Encoder and serial interface with D standard connectors,
»» Integrated ground bar (3xM4) for shields and groundings.
4 3 2 1 0 S C E
Status Enable
Communications
Alarm conditions
Drive condition Leds on Lighting mode Description
0, 1, 2, Fix Display the binary code of the active alarm.
Alarm 3, 4 Refer to chap. 9 for codes description
S 1 Hz flashing
4 3 2 1 0
Hardware Description | 33
5
Electrical
Connections
Phase Motion Control
AxM II / AxP Configurable Motion Control Platform
EtherCAT OUT EtherCAT IN
C1
S1
U2
U1
E1
Ground
Connection
R1
P1
USER CONNECTOR U1
To obtain a good
performance of
N Name Type Function Signal description
the analog input
1 R0P Analog input Direct differential input +/-10V, Zin = 10Kohm, connect the RxN
if not used connect to GND
pin to the reference
2 R0N Analog input Denied differential input +/-10V, Zin = 10Kohm, (suorce side) and
if not used connect to GND
apply the –10/+10V
3 AO0 Analog output Programmable output +/-10V f.s., 5 mA to the RxP pin.
4 GND Analog ground Reference ground Analog signals reference
USER CONNECTOR U2
N Name Type Function Signal description
13 GND Analog ground Reference ground Analog signals Reference
14 R1P Analog input Direct differential input +/-10V, Zin = 10Kohm, if not used,
connect to GND
15 R1N Analog input Direct differential input +/-10V, Zin = 10Kohm, if not used,
connect to GND
16 AO1 Analog output Programmable output +/-10V f.s., 5 mA
Electrical Connections | 37
5.2 Encoder Connector (E1)
To allow the connection of different encoders some pins have more than one function. Select
the encoder type in the system table to activate the right connection.
8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
Shield Connection:
To obtain a good connection without noise problems it is necessary to connect the shield of
the encoder cable both on motor and drive side.
Motor side: connect the shield to the connector frame or to the apposite screws or of
the terminal board
Drive side: connect the shield to the connector body.
8 7 6 5 4 3 2 1
Ultract III
Signal Connector
15 14 13 12 11 10 9
Size 1 - M23 - 17 Pin
PTC KTY
3
13
1
2
11
12
15
16
5
6
14
4
8 17
9 9
Electrical Connections | 39
Endat Encoder Connections Table
8 7 6 5 4 3 2 1
Ultract III
Signal Connector
15 14 13 12 11 10 9
Size 1 - M23 - 17 Pin
PTC KTY
3
13
5
14
7
10
4 8
17 9
WARNING
Maximum cable length with ENDAT encoder 40 mt
5 ---
6 + Vcc 5V / 7,5V Encoder supply Positive supply voltage
Auxiliary supply
7 ---
8 PTC / KTY Multifunction input Thermal sensor PTC or KTY ground
connected
9 ENDAT Multifunction input ENDAT data TTL
DATA -
10 ---
11 ---
12 ---
13 ---
14 ENDAT Digital input ENDAT data TTL
DATA +
15 ---
8 7 6 5 4 3 2 1
Ultract III
Signal Connector
15 14 13 12 11 10 9
Size 1 - M23 - 17 Pin
KTY PTC
1 4
11 11
14
9
15
16
2
3
5
13
12
Electrical Connections | 41
Resolver Connections Table:
8 7 6 5 4 3 2 1
Ultract III
Signal Connector
15 14 13 12 11 10 9
Size 1 - M23 - 17 Pin
KTY PTC
7
10
14
4
5
6
8 16
9 17
Adopt a cable with individually shielded twisted pairs and connect all the internal shields to
the pin 1 of the connector; connect the external shield to the connector body.
With the Resolver sensor, adopt a cable with individually shielded twisted pairs and connect
all the internal shields to the pin 1 of the connector; connect the external shield to the con-
nector body.
C1 connector can be used for CAN field bus line plus the auxiliary A- / Clock - CAN L
encoder signals or alternatively the encoder simolation. Index- Shield B+ / Data +
Electrical Connections | 43
5.5 AxM II size 1 POWER CONNECTIONs
0
9
8
7
6
5
4
3
2
1
and DC+. 8 BR- Brake terminal - Brake terminal Connect to the internal or external braking resistor
9 BR+ Brake terminal + Brake terminal Connect to the internal or external braking resistor
10 DC+ DC bus positive DC+bus parallel connection possible Rectified power supply
Power Connections of new AxM II drive differ from AxM 1 version. See Appendix.
3
2
1
AxM II
5 4 3 2 1
9 8 7 6
Gnd Tx Rx
5 4 3 2 1
9 8 7 6
HOST
Electrical Connections | 45
5.6 AxM II size 2 POWER CONNECTION
8
7
6
5
4
3
2
1
7 C1
Motor phase C Motor power supply Yellow / C
8 C2
3
2
1
AxM II
5 4 3 2 1
9 8 7 6
Gnd Tx Rx
5 4 3 2 1
9 8 7 6
HOST
Electrical Connections | 47
5.7 AxM II size 3 POWER CONNECTION
8
7
6
5
4
3
2
1
3
2
1
AxM II
5 4 3 2 1
9 8 7 6
Gnd Tx Rx
5 4 3 2 1
9 8 7 6
HOST
Electrical Connections | 49
5.8 AxM II size 4 POWER CONNECTION
Output
Input
1
2
3
8
7
6
5
4
3
2
1
5 4 3 2 1
9 8 7 6
Gnd Tx Rx
5 4 3 2 1
9 8 7 6
HOST
Electrical Connections | 51
5.9 AxM II size 5 POWER CONNECTION
Output
Input
1
2
3
7
6
5
4
3
2
1
5 4 3 2 1
9 8 7 6
Gnd Tx Rx
5 4 3 2 1
9 8 7 6
HOST
Electrical Connections | 53
5.10 Connection example
Make the jumper with 1,5 mm2 wire between BR+ and DC+ to use the internal braking resis-
tor. If an external resistor is connected to pins BR- and DC+ the jumper must not be done.
Software installation:
»» Connect the 24 V supply on +24 V and 0 V of the terminal board (see par. 8.1 for con-
nections outline of user connector U1).
»» Connect the RS 232 line to PC. In this condition the drive can be consulted and pro-
grammed. So far it is not necessary any power feeding.
Power connections:
»» Connect the motor terminals to the the A, B and C terminals of the drive’s power terminal
board, according to the sequence specified in the connection outline supplied with the
motor. Connect the power supply to the R, S and T of the power terminal board (see par.
8.4 for power connection outline P1). The cable shield must be grounded on both sides,
AxP drives are motor and drive, connecting it to the special screw provided for.
designed to work
with 2 or 3 phase
supply, the voltage
value must be less WARNING
than 230V (+10%). Correct performance of the drive requires a braking resistor connection. The internal braking
resistor can dissipate 10W only. To use it a connection between BR+ and DC+ must be done
AxM II drives are on the power terminal box P1. When a higher dissipation is required, an external suitable
designed to work resistor must be connected on the BR- and DC+ terminals of P1 terminal box. Minimum and
with 3 phase supply maximum ohmic values for the external resistor are shown in the par. 4.1. (see par. 8.4 for
only, the voltage power connection outline).
value must be less
than 460V (+10%). Position sensor connection:
»» Connect the position sensor to E1 port, through a suitable multipolar shielded cable. The
shield must be grounded on motor side and to connector body on drive side.
To configure the principal parameters in order to obtain any motor operation the con-
nection with the drive must be enabled (232 interface, port S1);
Initially all the parameters are displayed on red, because they are modified only in the PC
side. You can now read the actual configuaration from drive or write the modiified param-
eters to activate the new settings, in both case the parameters will displaied on black.
After the modification you made and download through the Write or Write all buttons, to The “Write All”
confirm the modifications and to maintain new parameters use the “save” button. selection enable the
tranfer of the visu-
alized parameters
only, but the “save”
selection enable the
storing of all the
parameters.
The main param-
eters you must
set are the poles
Parameters setting number of the mo-
The Motor, Encoder and PID parameters (in the system table) need usually to be configu- tor, the type and
rated depending from the selected motor; then Acceleration, Speed and Current limit must pulse number of the
be set on the application table. encoder. You have
also the nominal
and limit current.
Digital 6 DI6 Control Selector If this input is high the speed control is selected; if
-OPTIONAL- not the current control is selected. Selectable from
parameter
Analog 0 AI0 Speed Reference When the speed control is selected this analog input
changes the speed reference.
Analog 1 AI1 Current Ref. When the current control is selected this analog input
changes the current reference.
The drive activates the digital outputs related to its run state.
Press Enable button to enable drive receiving new firmware, then press Load to effectively
start code download. When finish Reset the drive.
We supply different kind of drive with different hardware settings so a files list are available.
It is important select the right file.SRE to download.
SysApp-1-4-291-xxxx-xx.sre
SysApp-1-4-291-xxxx-xx.sre
SysApp-1-4-291-xxxx-xx.sre The drive will
be unusable if
You can see the wich Hardware you have by selecting Service/Target Information menù: any troubles
occurs during the
Firmware download
operation (Ex. Lost
of 24V supply,
PC connection
problem, …).
Repeat the firmware
download setting
serial interface
parameters to Bit
Rate 38400 –
N,8,1 – address 0.
Select .SRE file with corresponding FPGA ID Type (FPGA ID Build has to be ignored).
»» Safety brakes designed for servo motors are stationary brakes. They are designed ex-
clusively to hold a motor still when deenergized, typically for vertical translations. They
are not designed to absorb any significant energy, also because their torque to size ratio
is extreme. If used to stop a motor, instead of keeping it at standstill, they would wear
quickly and eventually seize.
»» The braking torque of an electrically driven brushless motor is always higher than that of
the brake and the corresponding braking time is shorter.
The last column of the following table is the alarm code as shown on the panel’s leds.
7 4 3 2 1 0 S C E
8 Overcurrent The current reached a peak Check the current loop gain 4 3 2 1 0 S C E
12 4 3 2 1 0 S C E
13 4 3 2 1 0 S C E
14 4 3 2 1 0 S C E
configuration and
Endat encoder connections.
configuration,
Brake resistor connection
and power size
24 CAN fail CAN fieldbus physical layer error Check CAN configuration, 4 3 2 1 0 S C E
hardware connections,
CANOpen master
configuration, messages
overrun
25 EtherCAT fail EtherCAT fieldbus physical layer Check ethernet cables 4 3 2 1 0 S C E
27 Motor The PTC sensor has detected a Check the motor PTC 4 3 2 1 0 S C E
30 4 3 2 1 0 S C E
31 4 3 2 1 0 S C E
Error Codes | 65
9
CE
Conformity
Phase Motion Control
AxM II / AxP Configurable Motion Control Platform
9.1 Introduction: EC directives
The EC Directives are manufacturing prescriptions intended to guarantee a standard level of
quality, reliability and safety for all industrial goods produced and marketed across the Euro-
pean Union. The EC Directives are general documents that establish base specifications for
the certifications, which are subsequently converted into national laws by all member states.
A certification issued by a member state is valid automatically in all other member states.
Technical details are not included in the directives. They are determined by the relevant
European harmonized standards (EN).
After verification, affixing a CE mark certifies the conformity to the CE directives. Within the
EU there are no commercial barriers for a product with the CE mark. A conformity certificate,
however, is generally not required for most directives. Consequently, it is not always evident
which of the (so far) 21 EC directives is considered in the CE mark of a product and which
standards are considered in the conformity verification.
In the field of Brushless motor drives, the CE mark is referred exclusively to the Low Voltage
Directive. As for the EMCD directive, a drive is only a component and not a system, and the
conformity of the system to the EMCD remains the sole responsibility of the system designer
or user. In order to assist their Customers, Phase Motion Control have already proved and
certified the conformity of a CE-typical system to the EMC directive (see following chapter)
with the AxM digital platforms and the ULTRACT III brushless motors.
9.5 Installation
1. The units must be installed and cooled according to the regulations stated in the cor-
responding documentation
2. Ensure that no components are bent or insulation distances changed during transport.
The electronic components and contacts must not be touched.
3. When working on an energized controller the valid national requirements for the preven-
tion of accidents must be observed.
4. The electrical installation must comply with applicable regulations (cable cross sections,
fuses, protective conductor connections)
5. All control inputs and outputs of the drives are insulated with a “basic” insulation (func-
tional). Another level of protection must be implemented for personal safety against
electrical contact..
6. When using current-operated protective devices, please note that:
The controller have internal DC rectification. A DC fault current is therefore possible.
Some differential current protection systems are made inoperative by DC current leakage.
Use only “universal” or pulse operated protection devices.
The RFI filter which is built into the drives cause a certain amount of leakage current
to flow in the ground wires. This current may cause tripping of too sensitive differential
device and need to be taken into account while sizing differential devices.
7. Irrespective of the CE mark on both drives and motors, it is reminded that the compliance
of the required limit values with the legal EMC regulations remain the responsibility of
the manufacturer of the system or machine.
CE Conformity | 69
eration of radio and telecommunication systems and other equipment is possible and that a
suitable immunity of the equipment against electromagnetic disturbances is ensured so that
the operation can be achieved.
Controllers cannot be driven in stand-alone operation and therefore the controllers them-
selves cannot correspond to the EMC directive. The controllers must be integrated into a
drive system to check the compliance with the EC directive relating to EMC of the “Regula-
tion about the electromagnetic compatibility of devices”.
Phase Motion Control has verified the conformity of controllers integrated into a “typical”
drive system (see below). The user can use this example as a reference to design a system
in according to EMCD.
ULTRACT III series motors and AxM II / AxP brushless drives series are not stand-alone sys-
tems, and are specified to application fields 2 and 3 in accordance with IEC-22G-21/CDV.
CE Conformity | 71
10
Safety
Instructions
Appropriate Use
Introduction
PMC products represent state-of-the-art developments and manufacturing. They are tested
prior to delivery to ensure operating safety and reliability.
The products may only be used in the manner that is defined as appropriate. If they are used
in an inappropriate manner, then situations can develop that may lead to property damage
or injury to personnel.
Note: PMC as manufacturer is not liable for any damages resulting from inappropriate use.
In such cases, the guarantee and the right to payment of damages resulting from inappropri-
ate use are forfeited. The user alone carries all responsibility of the risks.
Before using PMC products, make sure that all the pre-requisites for an appropriate use of
the products are satisfied:
»» Personnel that in any way, shape or form uses our products must first read and under-
stand the relevant safety instructions and be familiar with appropriate use.
»» If the products take the form of hardware, then they must remain in their original state,
in other words, no structural changes are permitted. It is not permitted to decompile
software products or alter source codes.
»» Do not mount damaged or faulty products or use them in operation.
»» Make sure that the products have been installed in the manner described in the relevant
documentation.
Drive controllers made by PMC are designed to control electrical motors and monitor their
operation. Control and monitoring of the motors may require additional sensors and
actors.
Note: The drive controllers may only be used with the accessories and parts specified in
this document. If a component has not been specifically named, then it may not be either
mounted or connected. The same applies to cables and lines. Operation is only permitted
in the specified configurations and combinations of components using the software and
firmware as specified.
Every drive controller has to be programmed before commissioning, making it possible for
the motor to execute the specific functions of an application. The drive controllers have been
developed for use in single- and multiaxis drive and control tasks.
To ensure an application-specific use, the drive controllers are available with different drive
power and different interfaces.
Inappropriate Use
Using the drive controllers outside of the operating conditions described in this documenta-
tion and outside of the indicated technical data and specifications is defined as “inappro-
priate use”.
Drive controllers must not be used, if
»» ... they are subject to operating conditions that do not meet the specified ambient con-
ditions. This includes, for example, operation under water, under extreme temperature
fluctuations or extremely high maximum temperatures.
»» Furthermore, the drive controllers must not be used in applications which have not been
expressly authorized by PMC.
»» Please carefully follow the specifications outlined in the general Safety Instructions!
General Information
Improper use of these devices, failure to follow the safety instructions in this document or
tampering with the product, including disabling of safety devices, may result in material
damage, bodily harm, electric shock or even death! WARNING
»» PMC is not liable for damages resulting from failure to observe the warnings provided in
this documentation.
»» Read the operating, maintenance and safety instructions in your language before starting
up the machine. If you find that you cannot completely understand the documentation
for your product, please ask your supplier to clarify.
»» Proper and correct transport, storage, assembly and installation as well as care in opera-
Safety Instructions | 75
tion and maintenance are prerequisites for optimal and safe operation of this device.
»» Only assign trained and qualified persons to work with electrical installations:
Only persons who are trained and qualified for the use and operation of the device
may work on this device or within its proximity. The persons are qualified if they have
sufficient knowledge of the assembly, installation and operation of the equipment as
well as an understanding of all warnings and precautionary measures noted in these
instructions.
Furthermore, they must be trained, instructed and qualified to switch electrical cir-
cuits and devices on and off in accordance with technical safety regulations, to
ground them and to mark them according to the requirements of safe work practices.
They must have adequate safety equipment and be trained in first aid.
»» Only use spare parts and accessories approved by the manufacturer.
»» Follow all safety regulations and requirements for the specific application as practiced
in the country of use.
Warning symbol with signal word Degree of hazard seriousness according to ANSI Z 535
Death or severe bodily harm will occur.
DANGER
Death or severe bodily harm may occur.
WARNING
CAUTION
DANGER
DANGER
High electric voltage because of incorrect connection! Risk of death or bodily injury by
electric shock!
WARNING
Health hazard for persons with heart pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
WARNING
CAUTION
Electrical hazard due to water leakage on electrical component. Risk of injury by improper
handling! Risk of bodily injury by bruising, shearing, cutting, hitting, or improper handling of
pressurized lines!
DANGER
Note: This section only concerns devices and drive components with voltages of more than
50 Volt.
Contact with parts conducting voltages above 50 Volts can cause personal danger and
electric shock. When operating electrical equipment, it is unavoidable that some parts of
the devices conduct dangerous voltage.
High electrical voltage! Danger to life, electric shock and severe bodily injury!
DANGER
»» Only those trained and qualified to work with or on electrical equipment are permitted to
operate, maintain and repair this equipment.
»» Follow general construction and safety regulations when working on electrical power
installations.
»» Before switching on the device, the equipment grounding conductor must have been
nondetachably connected to all electrical equipment in accordance with the connection
diagram.
»» Do not operate electrical equipment at any time, even for brief measurements or tests, if
the equipment grounding conductor is not permanently connected to the mounting points
of the components provided for this purpose.
»» Before working with electrical parts with voltage potentials higher than 50 V, the device
must be disconnected from the mains voltage or power supply unit. Provide a safeguard
Safety Instructions | 77
to prevent reconnection.
»» With electrical drive and filter components, observe the following:
Wait 30 minutes after switching off power to allow capacitors to discharge before
beginning to work. Measure the voltage on the capacitors before beginning to work to
make sure that the equipment is safe to touch.
»» Never touch the electrical connection points of a component while power is turned on.
»» Install the covers and guards provided with the equipment properly before switching the
device on. Before switching the equipment on, cover and safeguard live parts safely to
prevent contact with those parts.
»» A residual-current-operated circuit-breaker or r.c.d. cannot be used for electric drives!
Indirect contact must be prevented by other means, for example, by an overcurrent pro-
tective device according to the relevant standards.
»» Secure built-in devices from direct touching of electrical parts by providing an external
housing, for example a control cabinet.
High housing voltage and large leakage current! Risk of death or bodily injury by electric
shock!
DANGER
»» Before switching on, the housings of all electrical equipment and motors must be con-
nected or grounded with the equipment grounding conductor to the grounding points.
This is also applicable before short tests.
»» The equipment grounding conductor of the electrical equipment and the units must be
non-detachably and permanently connected to the power supply unit at all times. The
leakage current is greater than 3.5 mA.
»» Over the total length, use copper wire of a cross section of a minimum of 10 mm2 for
this equipment grounding connection!
»» Before start-up, also in trial runs, always attach the equipment grounding conductor or
connect with the ground wire. Otherwise, high voltages may occur at the housing causing
electric shock
High electric voltage by incorrect connection! Risk of death or bodily injury by electric shock!
WARNING
»» To all connections and terminals with voltages between 0 and 50 Volt, only devices, elec-
trical components, and conductors may be connected which are equipped with a PELV
(Protective Extra-Low Voltage) system.
»» Connect only voltages and circuits which are safely isolated from dangerous voltages.
Safe isolation is achieved for example by isolating transformers, safe optocouplers or
battery operation without mains connection.
Dangerous movements can be caused by faulty control of connected motors. Some common
examples are:
Dangerous movements can occur immediately after equipment is switched on or even after
an unspecified time of trouble-free operation. The monitoring in the drive components will
normally be sufficient to avoid faulty operation in the connected drives. Regarding personal
safety, especially the danger of bodily harm and material damage, this alone cannot be relied
upon to ensure complete safety. Until the integrated monitoring functions become effective,
it must be assumed in any case that faulty drive movements will occur. The extent of faulty
drive movements depends upon the type of control and the state of operation.
Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage!
DANGER
»» For the above reasons, ensure personal safety by means of qualified and tested higher-
level monitoring devices or measures integrated in the installation. They have to be
provided for by the user according to the specific conditions within the installation and
a hazard and fault analysis. The safety regulations applicable for the installation have to
be taken into consideration. Unintended machine motion or other malfunction is possible
if safety devices are disabled, bypassed or not activated.
»» Keep free and clear of the machine’s range of motion and moving parts. Possible mea-
sures to prevent people from accidentally entering the machine’s range of motion:
use safety fences
use safety guards
use protective coverings
install light curtains or light barriers
»» Fences and coverings must be strong enough to resist maximum possible momentum.
»» Mount the emergency stop switch in the immediate reach of the operator. Verify that the
emergency stop works before startup. Don’t operate the device if the emergency stop is
not working.
»» Isolate the drive power connection by means of an emergency stop circuit or use a safety
related starting lockout to prevent unintentional start.
»» Make sure that the drives are brought to a safe standstill before accessing or entering
the danger zone.
»» Additionally secure vertical axes against falling or dropping after switching off the motor
power by, for example:
mechanically securing the vertical axes,
adding an external braking/ arrester/ clamping mechanism or
ensuring sufficient equilibration of the vertical axes.
The standard equipment motor brake or an external brake controlled directly by the drive
controller are not sufficient to guarantee personal safety!
»» Disconnect electrical power to the equipment using a master switch and secure the
switch against reconnection for:
maintenance and repair work
cleaning of equipment
long periods of discontinued equipment use
»» Prevent the operation of high-frequency, remote control and radio equipment near elec-
tronics circuits and supply leads. If the use of such devices cannot be avoided, verify the
Safety Instructions | 79
system and the installation for possible malfunctions in all possible positions of normal
use before initial startup. If necessary, perform a special electromagnetic compatibility
(EMC) test on the installation.
Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting
Health hazard for persons with heart pacemakers, metal implants and hearing aids in prox-
WARNING
imity to electrical equipment!
»» Persons with heart pacemakers and metal implants are not permitted to enter following
areas:
Areas in which electrical equipment and parts are mounted, being operated or com-
missioned.
Areas in which parts of motors with permanent magnets are being stored, repaired or
mounted.
»» If it is necessary for somebody with a pacemaker to enter such an area, a doctor must
be consulted prior to doing so. The interference immunity of present or future implanted
heart pacemakers differs greatly, so that no general rules can be given.
»» Those with metal implants or metal pieces, as well as with hearing aids must consult a
doctor before they enter the areas described above. Otherwise health hazards may occur.
Hot surfaces at motor housings, on drive controllers or chokes! Danger of injury! Danger of
CAUTION
burns!
»» Do not touch surfaces of device housings and chokes in the proximity of heat sources!
Danger of burns!
»» Do not touch housing surfaces of motors! Danger of burns!
»» According to operating conditions, temperatures can be higher than 60 °C, 140 °F during
or after operation.
»» Before accessing motors after having switched them off, let them cool down for a suf-
ficiently long time. Cooling down can require up to 140 minutes! Roughly estimated, the
time required for cooling down is five times the thermal time constant specified in the
Technical Data.
»» After switching drive controllers or chokes off, wait 15 minutes to allow them to cool
down before touching them.
»» Wear safety gloves or do not work at hot surfaces.
»» For certain applications, the manufacturer of the end product, machine or installation,
according to the respective safety regulations, has to take measures to avoid injuries
caused by burns in the end application. These measures can be, for example: warnings,
guards (shielding or barrier), technical documentation.
Safety Instructions | 81
Appendix